Manufacture of a conformable pressure vessel

ABSTRACT

A method of manufacturing a high-pressure fluid vessel includes forming a first portion of a high-pressure fluid vessel with a molding process. The high-pressure fluid vessel includes a stack of capsules. Each capsule includes a first domed end, a second domed end, and a semicylindrical portion extending between and connecting the first domed end to the second domed end. The method further includes forming a second portion of a high-pressure fluid vessel with the molding process. The second portion of the high-pressure fluid vessel is positioned adjacent to the first portion of the high-pressure fluid vessel. The second portion of the high-pressure fluid vessel is welded to the first portion of the high-pressure fluid vessel.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a divisional of U.S. application Ser. No. 15/706,117filed Sep. 15, 2017, for “Design and Manufacture of a ConformablePressure Vessel” by Wenping Zhao and Ellen Y. Sun.

BACKGROUND

The present disclosure relates to high-pressure fluid vessels. Morespecifically, the present disclosure relates to high-pressure fluidvessels for use in aircraft potable water systems.

Aircraft potable water systems supply drinkable water throughout anaircraft for various uses. Aircraft potable water systems typicallyinclude many parts, including but not limited to: fluid vessels,hydraulic pumps, fluid heaters, control valves, and hydraulic fluid linetubing. The fluid vessels used for aircraft potable water vessels aregenerally pressurized and must maintain their shape while under internalpressure. The preferred shape for high-pressure fluid vessels is acylindrical or spherical shape because there are few corners, reducingthe number of stress concentration locations.

With that said, high-pressure fluid vessels for aircraft potable watersystems must fit into a limited space, shape, and size thatsignificantly deviates from the cylindrical or spherical shape preferredby pressurized vessels. Further, as with any other aircraft components,the high-pressure fluid vessel must be lightweight to meet aircraftweight restrictions. These requirements present significant design andmanufacturing challenges for high-pressure vessels in aircraft potablewater systems.

SUMMARY

A method of manufacturing a high-pressure fluid vessel includes forminga first portion of a high-pressure fluid vessel with a molding process.The high-pressure fluid vessel includes a stack of capsules. Eachcapsule includes a first domed end, a second domed end, and asemicylindrical portion extending between and connecting the first domedend to the second domed end. The method further includes forming asecond portion of a high-pressure fluid vessel with the molding process.The second portion of the high-pressure fluid vessel is positionedadjacent to the first portion of the high-pressure fluid vessel. Thesecond portion of the high-pressure fluid vessel is welded to the firstportion of the high-pressure fluid vessel.

A method of manufacturing a high-pressure fluid vessel includes forminga plurality of liners with a molding process. A first composite materialis wrapped around each of the liners to form a plurality ofcompartments. An aperture is formed in each of the plurality ofcompartments. The plurality of compartments are positioned adjacent toone another. A second composite material is wrapped around the pluralityof compartments to form a high-pressure fluid vessel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a schematic of an aircraft with a potable water system.

FIG. 1B is a cross-sectional view of an aircraft fuselage, showing afirst embodiment of a high-pressure fluid vessel.

FIG. 2A is a front view of the high-pressure fluid vessel of FIG. 1B.

FIG. 2B is a perspective cross-sectional view of the high-pressure fluidvessel taken along line 2B-2B of FIG. 2A.

FIG. 3 is a side cross-sectional view of the high-pressure fluid vesselof FIG. 2A.

FIG. 4 is a side cross-sectional view of the high-pressure fluid vesselof FIG. 2A, showing an internal liner.

FIG. 5 is a side cross-sectional view of the high-pressure fluid vesselof FIG. 2A, showing the design method and summation of forces.

FIG. 6 is a perspective view of a second embodiment of a high-pressurefluid vessel.

FIG. 7 is a flow chart of a first method for manufacturing ahigh-pressure fluid vessel.

FIG. 8 is a flow chart of a second method for manufacturing ahigh-pressure fluid vessel.

DETAILED DESCRIPTION

FIG. 1A is a schematic of aircraft 10 with potable water system 12,which includes hydraulic pump 14, control valve 16, point of use 17, andhigh-pressure fluid vessel 18. FIG. 1B is a cross-sectional view ofaircraft 10, showing conformable tank 18, external fuselage structure20, and internal aircraft structure 22.

Potable water system 12 is situated in an aft portion of aircraft 10.Within potable water system 12, hydraulic tubes, lines, or hoses connecthydraulic pump 14, control valve 16, point of use 17, and high-pressurefluid vessel 18. Fluid flow within potable water system 12 is induced byhydraulic pump 14. Control of the fluid flow within potable water system12 is achieved by utilizing control valve 16. Potable water, for use inpotable water system 12, is stored at an elevated pressure withinhigh-pressure fluid vessel 18, as compared to ambient pressure outsidehigh-pressure fluid vessel 18.

As shown in FIG. 1B, high-pressure fluid vessel 18 is configured toconform to both external fuselage structure 20 and internal aircraftstructure 22. The portion of high-pressure fluid vessel 18 closest toexternal fuselage structure 20 is curved to conform to the curvature ofexternal fuselage structure 20. Likewise, the portion of high-pressurefluid vessel 18 closest to internal aircraft structure 22 is more orless flat to conform to internal aircraft structure 22. FIG. 1B showsone embodiment of conformable high-pressure fluid vessel 18 and is notmeant to limit the disclosure to a single embodiment. High-pressurefluid vessel 18 is conformable for use in a plurality of irregularaircraft spaces.

FIG. 2A is a front view of high-pressure fluid vessel 18. FIG. 2B is aperspective cross-sectional view of high-pressure fluid vessel 18 takenalong line 2B-2B of FIG. 2A. High-pressure fluid vessel 18 includesbottom compartment 24, intermediate compartments 26, 28, and 30, and topcompartment 32. Bottom compartment 24 includes capsule 33A with firstdomed end 34A, second domed end 36A (shown in FIG. 2A), semicylindricalportion 38A, and cavity 40A (shown in FIG. 2B). Intermediate compartment26 includes capsule 33B with first domed end 34B, second domed end 36B(shown in FIG. 2A), semicylindrical portion 38B, and cavity 40B (shownin FIG. 2B). Intermediate compartment 28 includes capsule 33C with firstdomed end 34C, second domed end 36C (shown in FIG. 2A), semicylindricalportion 38C, and cavity 40C (shown in FIG. 2B). Intermediate compartment30 includes capsule 33D with first domed end 34D, second domed end 36D(shown in FIG. 2A), semicylindrical portion 38D, and cavity 40D (shownin FIG. 2B). Top compartment 32 includes capsule 33E with first domedend 34E, second domed end 36E (shown in FIG. 2B), semicylindricalportion 38E, and cavity 40E (shown in FIG. 2B). High-pressure fluidvessel 18 further includes internal supports 42, 44, 46, and 48 (shownin FIG. 2B). Internal support 42 includes apertures 50A (shown in FIG.2B). Internal support 44 includes aperture 50B (shown in FIG. 2B).Internal support 46 includes aperture 50C (shown in FIG. 2B). Internalsupport 48 includes aperture 50D (shown in FIG. 2B).

Located at the base of high-pressure fluid vessel 18 is bottomcompartment 24, which is located below and connected to intermediatecompartment 26. Intermediate compartment 26 is located below andconnected to intermediate compartment 28. Intermediate compartment 28 islocated below and connected to intermediate compartment 30. Intermediatecompartment 30 is located below and connected to top compartment 32. Inthe embodiment shown, high-pressure fluid vessel 18 has threeintermediate compartments 26, 28, and 30. In an alternate embodiment,high pressure fluid vessel 18 can include any number of intermediatecompartments or no intermediate compartments.

Capsules 33A, 33B, 33C, 33D, and 33E are convex curved shaped bodyportions of bottom compartment 24, intermediate compartments 26, 28, and30, and top compartment 32, respectively. Capsule 33A of bottomcompartment 24 includes first domed end 34A, second domed end 36A, andsemicylindrical portion 38A extending between and connecting first domedend 34A and second domed end 36A. Cavity 40A is positioned in bottomcompartment 24 and is defined by capsule 33A. Capsule 33B ofintermediate compartment 26 comprises first domed end 34B, second domedend 36B, and semicylindrical portion 38B extending between andconnecting first domed end 34B and second domed end 36B. Cavity 40B ispositioned in intermediate compartment 26 and is defined by capsule 33B.Capsule 33C of intermediate compartment 28 includes first domed end 34C,second domed end 36C, and semicylindrical portion 38C extending betweenand connecting first domed end 34C and second domed end 36C. Cavity 40Cis positioned in intermediate compartment 28 and is defined by capsule33C. Capsule 33D of intermediate compartment 30 includes first domed end34D, second domed end 36D, and semicylindrical portion 38D extendingbetween and connecting first domed end 34D and second domed end 36D.Cavity 40D is positioned in intermediate compartment 30 and is definedby capsule 33D. Capsule 33E of top compartment 32 includes first domedend 34E, second domed end 36E, and semicylindrical portion 38E extendingbetween and connecting first domed end 34E and second domed end 36E.Cavity 40E is positioned in top compartment 32 and is defined by capsule33E.

First domed ends 34A, 34B, 34C, 34D, and 34E and second domed ends 36A,36B, 36C, 36D, and 36E are semispherical shaped. Semicylindricalportions 38A, 38B, 38C, 38D, and 38E are right circular cylindricalshaped where a cross-section of the semicylindrical portions 38A, 38B,38C, 38D, and 38E are circular shaped.

Internal supports 42, 44, 46, and 48 are positioned in high-pressurefluid vessel 18 to provide structural support for high-pressure fluidvessel 18. Internal supports 42, 44, 46, and 48 are baffles in theembodiment shown in FIGS. 2A-2B. Internal support 42 is positionedbetween bottom compartment 24 and intermediate compartment 26. Internalsupport 44 is positioned between intermediate compartment 26 andintermediate compartment 28. Internal support 46 is positioned betweenintermediate compartment 28 and intermediate compartment 30. Internalsupport 48 is positioned between intermediate compartment 30 and topcompartment 32.

Aperture 50A extends through internal support 42 to connect bottomcompartment 24 to intermediate compartment 26. Aperture 50B extendsthrough internal support 44 to connect intermediate compartment 26 tointermediate compartment 28. Aperture 50C extends through internalsupport 46 to connect intermediate compartment 28 to intermediatecompartment 30. Aperture 50D extends through internal support 48 toconnect intermediate compartment 30 to top compartment 32. In alternateembodiments, internal supports 42, 44, 46, and 48 can include one ormore apertures 50A, 50B, 50C, and 50D, each aperture being of equal orvarying size.

High-pressure fluid vessel 18 is capable of holding potable water onaircraft 10. High-pressure fluid vessel 18 includes bottom compartment24, intermediate compartments 26, 28, and 30, and top compartment 32that are designed to conform to aircraft 10. High-pressure fluid vessel18 includes internal supports 42, 44, 46, and 48 to provide structuralsupport to high-pressure fluid vessel 18 to prevent high-pressure fluidvessel 18 from deforming under pressure. Apertures 50A, 50B, 50C, and50D extend through internal supports 42, 44, 46, and 48 respectively, toallow potable water to flow through high-pressure fluid vessel 18.

FIG. 3 is a side cross-sectional view of high-pressure fluid vessel 18.High-pressure fluid vessel 18 includes bottom compartment 24,intermediate compartments 26, 28, and 30, and top compartment 32 withcapsules 33A, 33B, 33C, 33D, and 33E having first domed ends 34A, 34B,34C, 34D, and 34E (shown in FIGS. 2A-2B), second domed ends 36A, 36B,36C, 36D, and 36E (shown in FIG. 2A), semicylindrical portions 38A, 38B,38C, 38D, and 38E, and cavities 40A, 40B, 40C, 40D, and 40E,respectively. High-pressure fluid vessel 18 further includes internalsupports 42, 44, 46, and 48, with apertures 50A, 50B, 50C, and 50D,respectively. Semicylindrical portions 38A, 38B, 38C, 38D, and 38Einclude curved external walls 52A, 52B, 52C, 52D, and 52E, innersurfaces 54A, 54B, 54C, 54D, and 54E, and outer surfaces 56A, 56B, 56C,56D, and 56E, respectively. Also shown in FIG. 3 are first intersectionlocations 58A, 58B, 58C, and 58D and second intersection locations 60A,60B, 60C, and 60D.

High-pressure fluid vessel 18 includes bottom compartment 24 at a base,intermediate compartments 26, 28, and 30, and top compartment 32 at atop. Capsules 33A, 33B, 33C, 33D, and 33E are arcuate shaped bodyportions of bottom compartment 24, intermediate compartments 26, 28, and30, and top compartment 32, respectively. Bottom compartment 24 includescapsule 33A with first domed end 34A opposite of second domed end 36Aand semicylindrical portion 38A extending there between. Cavity 40A isformed in bottom compartment 24. Intermediate compartment 26 includescapsule 33B with first domed end 34B opposite of second domed end 36Band semicylindrical portion 38C extending there between. Cavity 40B isformed in intermediate compartment 26. Intermediate compartment 28includes capsule 33C with first domed end 34C opposite of second domedend 36C and semicylindrical portion 38C extending there between. Cavity40C is formed in intermediate compartment 28. Intermediate compartment30 includes capsule 33D with first domed end 34D opposite of seconddomed end 36D and semicylindrical portion 38D extending there between.Cavity 40D is formed in intermediate compartment 30. Top compartment 32includes capsule 33E with first domed end 34E opposite of second domedend 36E and semicylindrical portion 38E extending there between. Cavity40E is formed in top compartment 32.

High-pressure fluid vessel 18 further includes internal supports 42, 44,46, and 48. Internal support 42 is positioned between bottom compartment24 and intermediate compartment 26, and aperture 50A extends throughinternal support 42. Internal support 44 is positioned betweenintermediate compartment 26 and intermediate compartment 28, andaperture 50B extends through internal support 44. Internal support 46 ispositioned between intermediate compartment 28 and intermediatecompartment 30, and aperture 50C extends through internal support 46.Internal support 48 is positioned between intermediate compartment 30and top compartment 32, and aperture 50D extends through internalsupport 48.

High-pressure fluid vessel 18 will include a port to fill high-pressurefluid vessel 18. The port is preferably positioned in top compartment32, but can be positioned in any of bottom compartment 24, intermediatecompartments 26, 28, 30, and top compartment 32. Water can be put intoand released from high-pressure fluid vessel 18 through the port. Thewater in high-pressure fluid vessel 18 will move between bottomcompartment 24, intermediate compartments 26, 28, 30, and topcompartment 32 by flowing through apertures 50A, 50B, 50C, and 50D.Apertures 50A, 50B, 50C, and 50D can be any size and shape and there canbe multiple apertures 50A, 50B, 50C, and 50D in internal supports 42,44, 46, and 48 in alternate embodiments.

High-pressure fluid vessel 18 is designed to conform to a space onaircraft 10 (see FIG. 1B). Semicylindrical portions 38A, 38B, 38C, 38D,and 38E of bottom compartment 24, intermediate compartments 26, 28, and30, and top compartment 32, respectively, are curved to helphigh-pressure fluid vessel 18 conform to the space on aircraft 10 and toreduce stresses in semicylindrical portions 38A, 38B, 38C, 38D, and 38E.

Semicylindrical portion 38A of bottom compartment 24 includes curvedexternal wall 52A. Curved external wall 52A includes concave innersurface 54A and convex outer surface 56A. Semicylindrical portion 38B ofintermediate compartment 26 includes curved external wall 52B. Curvedexternal wall 52B further includes concave inner surface 54B and convexouter surface 56B. Semicylindrical portion 38C of intermediatecompartment 28 includes curved external wall 52C. Curved external wall52C includes concave inner surface 54C and convex outer surface 56C.Semicylindrical portion 38D of intermediate compartment 30 includescurved external wall 52D. Curved external wall 52D further includesconcave inner surface 54D and convex outer surface 56D. Semicylindricalportion 38E of top compartment 32 includes curved external wall 52E.Curved external wall 52E includes concave inner surface 54E and convexouter surface 56E.

High-pressure fluid vessel 18 includes a flat side portion and a curvedside portion. The flat side portion is the side in which a tangent linecan be drawn from curved external wall 52A to curved external wall 52Eand approximately only contact curved external walls 52B, 52C, and 52Dat a single tangent point of each; the right side of high-pressure fluidvessel 18 as oriented in FIG. 3 . The curved side portion is the sideopposite the flat side portion; the left side of high-pressure fluidvessel 18 as oriented in FIG. 3 .

Curved external walls 52A, 52B, 52C, 52D, and 52E abut one another atfirst intersection locations 58A, 58B, 58C, and 58D and secondintersection locations 60A, 60B, 60C, and 60D, respectfully. Bottomcompartment 24 is connected to intermediate compartment 26 at firstintersection location 58A and second intersection location 60A.Intermediate compartment 26 is connected to intermediate compartment 28at first intersection location 58B and second intersection location 60B.Intermediate compartment 28 is connected to intermediate compartment 30at first intersection location 58C and second intersection location 60C.Intermediate compartment 30 is connected to top compartment 32 at firstintersection location 58D and second intersection location 60D.

Located on the flat side portion of high-pressure fluid vessel 18 arefirst intersection locations 58A, 58B, 58C, and 58D. The intersection ofcurved external wall 52A and curved external wall 52B defines firstintersection location 58A. The intersection of curved external wall 52Band curved external wall 52C defines first intersection location 58B.The intersection of curved external wall 52C and curved external wall52D defines first intersection location 58C. The intersection of curvedexternal wall 52D and curved external wall 52E defines firstintersection location 58D.

Located on the curved side portion of high-pressure fluid vessel 18 aresecond intersection locations 60A, 60B, 60C, and 60D. The intersectionof curved external wall 52A and curved external wall 52B defines secondintersection location 60A. The intersection of curved external wall 52Band curved external wall 52C defines second intersection location 60B.The intersection of curved external wall 52C and curved external wall52D defines second intersection location 60C. The intersection of curvedexternal wall 52D and curved external wall 52E defines secondintersection location 60D.

According to the present disclosure, high-pressure fluid vessel 18 mustinclude at least two compartments connected at a first intersectionlocation and a second intersection location. High-pressure fluid vessel18, in its smallest form, includes bottom compartment 24 and topcompartment 32 connected at a first intersection location and a secondintersection location. With that said, high-pressure fluid vessel 18 isnot limited to a maximum number of compartments and intersectionlocations; high-pressure fluid vessel 18 can include as manycompartments and intersection locations as necessary to conform to anirregular shape or space. The high-pressure fluid vessel described inthe preceding paragraphs is a representation of a single embodiment andnot meant to limit the disclosure to this particular embodiment.

As shown in FIG. 1B and discussed above, high-pressure fluid vessel 18curves to conform to external fuselage structure 20. The curvaturedescribed is achieved by bottom compartment 24, intermediatecompartments 26, 28, and 30, and top compartment 32 having differentvolumes and radii. Bottom compartment 24 has the largest volume andradius, intermediate compartment 26 has a volume and radius that issmaller than bottom compartment 24, intermediate compartment 28 has avolume and radius that is smaller than intermediate compartment 26,intermediate compartment 30 has a volume and radius that is smaller thanintermediate compartment 28, and top compartment 32 has the smallestvolume and radius. The radii of first domed ends 34A, 34B, 34C, 34D, and34E, second domed ends 36A, 36B, 36C, 36D, and 36E, and semicylindricalportions 38A, 38B, 38C, 38D, and 38E, respectively, are preferably thesame for each of capsule 33A, 33B, 33C, 33D, and 33E. The curvature ofhigh-pressure fluid vessel 18 is achieved by curved external walls 52A,52B, 52C, 52D, and 52E having different volumes and radii whilemaintaining the flat side portion of high-pressure fluid vessel 18. Withthe flat side portion being held constant and the compartments volumeand radii being different, the curved side portion is formed. Thecurvature of the curved side portion can be varied by modifying thevolume and radii of each compartment. In the embodiment shown,high-pressure fluid vessel 18 includes five compartments, each ofdifferent volumes and radii. In all embodiments of high-pressure fluidvessel 18, at least two of the compartments must be of different volumesand radii.

High-pressure fluid vessel 18 further includes internal supports 42, 44,46, and 48 to prevent bottom compartment 24, intermediate compartments26, 28, 30, and top compartment 32 from deforming under internalpressure. Internal supports 42, 44, 46, and 48 include apertures 50A,50B, 50C, and 50D, respectively.

Internal support 42 extends from first intersection location 58A tosecond intersection location 60A. Internal support 44 extends from firstintersection location 58B to second intersection location 60B. Internalsupport 46 extends from first intersection location 58C to secondintersection location 60C. Internal support 48 extends from firstintersection location 58D to second intersection location 60D.

High-pressure fluid vessel 18 would deform under internal pressurewithout internal supports 42, 44, 46, and 48. Internal supports 42, 44,46, and 48 provide structural support to curved external walls 52A, 52B,52C, 52D, and 52E. Further, internal supports 42, 44, 46, and 48, arestrategically placed to evenly distribute the stresses in curvedexternal walls 52A, 52B, 52C, 52D, and 52E. This results in ahigh-pressure vessel that is high strength and structurally efficient.

FIG. 4 is a side cross-sectional view of high-pressure vessel 18. Asdiscussed earlier, high-pressure fluid vessel 18 includes bottomcompartment 24, intermediate compartments 26, 28, and 30, and topcompartment 32, and internal supports 42, 44, 46, and 48. Bottomcompartment 24, intermediate compartments 26, 28, and 30, and topcompartment 32 include inner surfaces 54A, 54B, 54C, 54D and 54E,respectively. In the embodiment shown, high-pressure fluid vessel 18further includes bottom liner 62, intermediate liners 64, 66, and 68,and top liner 70. Bottom liner 62, intermediate liners 64, 66, and 68,and top liner 70 include inner surfaces 72A, 72B, 72C, 72D, and 72E andouter surface 74A, 74B, 74C, 74D, and 74E, respectively.

High-pressure fluid vessel 18 includes bottom compartment 24,intermediate compartments 26, 28, and 30, and top compartment 32.Internal supports 42, 44, 46, and 48 extend between bottom compartment24, intermediate compartments 26, 28, and 30, and top compartment 32.Bottom compartment 24, intermediate compartments 26, 28, and 30, and topcompartment 32 have inner surfaces 54A, 54B, 54C, 54D and 54E,respectively. High-pressure fluid vessel 18 further includes bottomliner 62, intermediate liners 64, 66, and 68, and top liner 70. Bottomliner 62 includes inner surface 72A and outer surface 74A. Intermediateliner 64 includes inner surface 72B and outer surface 74B. Intermediateliner 66 includes inner surface 72C and outer surface 74C. Intermediateliner 68 includes inner surface 72D and outer surface 74D. Top liner 70includes inner surface 72E and outer surface 74E.

Outer surface 74A of bottom liner 62 is configured to abut inner surface54A of bottom compartment 24 and internal support 42. Outer surface 74Bof intermediate liner 64 is configured to abut inner surface 54B ofintermediate compartment 26, internal support 42, and internal support44. Outer surface 74C of intermediate liner 66 is configured to abutinner surface 54C of intermediate compartment 28, internal support 44,and internal support 46. Outer surface 74D of intermediate liner 68 isconfigured to abut inner surface 54D of intermediate compartment 30,internal support 46, and internal support 48. Outer surface 74E of topliner 70 is configured to abut inner surface 54E of top compartment 32,and internal support 48.

According to one embodiment, bottom liner 62, intermediate liners 64,66, and 68, and top liner 70 are included within high-pressure fluidvessel 18 to help seal and prevent fluid leakage from high-pressurefluid vessel 18. According to another embodiment, bottom liner 62,intermediate liners 64, 66, and 68, and top liner 70 are not includedwithin high-pressure fluid vessel 18 because bottom compartment 24,intermediate compartments 26, 28, and 30, and top compartment 32 aresufficiently connected and sealed in which fluid leakage is not aconcern.

FIG. 5 is a side cross-sectional view of high-pressure fluid vessel 18,showing the tank design method and summation of forces. FIG. 5 showsbottom compartment 24, intermediate compartment 26, internal support 42,curved external walls 52A and 52B, first intersection location 58A, andsecond intersection location 60A. FIG. 5 further includes forces F_(h),F_(c1), and F_(c2), which represent the forces present at firstintersection location 58A.

High-pressure fluid vessel 18 includes bottom compartment 24 that ispositioned below and attached to intermediate compartment 26 withinternal support 42 extending between bottom compartment 24 andintermediate compartment 26. Bottom compartment 24 has curved externalwall 52A and intermediate compartment 26 has curved external wall 52B.

First intersection location 58A is the location in which curved externalwall 52A of bottom compartment 24 intersects with curved external wall52B of intermediate compartment 26 and with internal support 42. Animportant design criterion of high-pressure vessel 18 is that thesummation of force at each and every intersection location (includingfirst intersection locations 58A, 58B, 58C, and 58D and secondintersection locations 60A, 60B, 60C, and 60D as shown in FIG. 3 ) ofhigh-pressure fluid vessel 18 must be zero and the directions of theforces do not change significantly during tank pressurization. The forcediagram of FIG. 5 represents a simplified version of the forces that arepresent at first intersection location 58A. In order for high-pressurefluid vessel 18 to maintain its shape under internal pressure, forcesF_(h), F_(c1), and F_(c2) must cancel each other out and equal zero. Ifthe summation of force at the intersection locations does not equalzero, high-pressure fluid vessel 18 will deform and significantlydeviate from its initial designed shape under internal pressure.

Although high-pressure vessel 18 has been described with reference tospecific embodiments and applications, high-pressure vessel 18 may varyin size and shape for applications where an irregular shaped pressurevessel is desired. High-pressure vessel 18 has been described as beingconfigured to store potable water, but in alternate embodimentshigh-pressure vessel 18 may also be used to store any other pressurizedfluid. High-pressure vessel 18 may be constructed using metal,composite, or other materials; a composite material being the preferredmaterial due to strength and weight characteristics.

High-pressure vessel 18 provides a verified conformable pressure vesseldesign method for efficient use of a given irregular space.High-pressure vessel 18 is of a structurally efficient design, whichresults in a high strength and lightweight high-pressure vessel 18. Thedesign method of high-pressure vessel 18 combined with compositematerials would provide the benefit of a high strength, lightweight, andconformable high-pressure vessel 18.

FIG. 6 is a perspective view of high-pressure fluid vessel 118.High-pressure fluid vessel 118 includes bottom compartment 124,intermediate compartments 126, 128, and 130, and top compartment 132.Bottom compartment 124 includes capsule 133A with first domed end 134A,second domed end 136A, semicylindrical portion 138A, and cavity 140A.Intermediate compartment 126 includes capsule 133B with first domed end134B, second domed end 136B, semicylindrical portion 138B, and cavity140B. Intermediate compartment 128 includes capsule 133C with firstdomed end 134C, second domed end 136C, semicylindrical portion 138C, andcavity 140C. Intermediate compartment 130 includes capsule 133D withfirst domed end 134D, second domed end 136D, semicylindrical portion138D, and cavity 140D. Top compartment 132 includes capsule 133E withfirst domed end 134E, second domed end 136E, semicylindrical portion138E, and cavity 140E.

Located at the base of high-pressure fluid vessel 118 is bottomcompartment 124, which is located below and connected to intermediatecompartment 126. Intermediate compartment 126 is located below andconnected to intermediate compartment 128. Intermediate compartment 128is located below and connected to intermediate compartment 130.Intermediate compartment 130 is located below and connected to topcompartment 132. In the embodiment shown, high-pressure fluid vessel 118has three intermediate compartments 126, 128, and 130. In an alternateembodiment, high pressure fluid vessel 118 can include any number ofintermediate compartments or no intermediate compartments.

Capsules 133A, 133B, 133C, 133D, and 133E are convex curved shaped bodyportions of bottom compartment 124, intermediate compartments 126, 128,and 130, and top compartment 132, respectively. Capsule 133A of bottomcompartment 124 includes first domed end 134A, second domed end 136A,and semicylindrical portion 138A extending between and connecting firstdomed end 134A and second domed end 136A. Cavity 140A is positioned inbottom compartment 124 and is defined by capsule 133A. Capsule 133B ofintermediate compartment 126 comprises first domed end 134B, seconddomed end 136B, and semicylindrical portion 138B extending between andconnecting first domed end 134B and second domed end 136B. Cavity 140Bis positioned in intermediate compartment 126 and is defined by capsule133B. Capsule 133C of intermediate compartment 128 includes first domedend 134C, second domed end 136C, and semicylindrical portion 138Cextending between and connecting first domed end 134C and second domedend 136C. Cavity 140C is positioned in intermediate compartment 128 andis defined by capsule 133C. Capsule 133D of intermediate compartment 130includes first domed end 134D, second domed end 136D, andsemicylindrical portion 138D extending between and connecting firstdomed end 134D and second domed end 136D. Cavity 140D is positioned inintermediate compartment 130 and is defined by capsule 133D. Capsule133E of top compartment 132 includes first domed end 134E, second domedend 136E, and semicylindrical portion 138E extending between andconnecting first domed end 134E and second domed end 136E. Cavity 140Eis positioned in top compartment 132 and is defined by capsule 133E.

High-pressure fluid vessel 118 is a second embodiment of tank 18 asshown in FIGS. 1A-5 . High-pressure fluid vessel 118 can be positionedbetween external fuselage structure 20 and internal aircraft structure22, as shown in FIG. 1B. High-pressure fluid vessel 118 has the sameproperties of high-pressure fluid vessel 18 shown in FIGS. 1A-5 , butthe shape of the compartments is different. First domed ends 134A, 134B,134C, 134D, and 134E and second domed ends 136A, 136B, 136C, 136D, and136E are semiellipsoidal shaped or torispherical shaped. Semicylindricalportions 138A, 138B, 138C, 138D, and 138E are elliptic cylindricalshaped where a cross-section of the semicylindrical portions 138A, 138B,138C, 138D, and 138E are ellipse shaped. Having semiellipsoidal shapedor torispherical shaped first domed ends 134A, 134B, 134C, 134D, and134E and second domed ends 136A, 136B, 136C, 136D, and 136E allowshigh-pressure fluid vessel 118 to be wider, allowing high-pressure fluidvessel 118 to be designed to fit into any space on an aircraft.

FIG. 7 is a flow chart of a first method for manufacturing ahigh-pressure fluid vessel. FIG. 7 shows steps 200-214. Steps 200-214can be used to manufacture high-pressure fluid vessel 18 shown in FIGS.1A-5 , high-pressure fluid vessel 118 shown in FIG. 6 , or any otherhigh-pressure fluid vessel. The following discussion will focus onhigh-pressure fluid vessel 18, but it is understood that this processcan be used to manufacture any other suitable tank.

Step 200 includes forming a first portion of a high-pressure fluidvessel using a molding process. Step 202 includes forming a secondportion of the high-pressure fluid vessel using a molding process. Step204 includes forming a plurality of internal supports using a moldingprocess. The molding process can include injection molding, compressionmolding, or any other suitable molding process. Steps 200, 202, and 204can be performed in any order. The high-pressure fluid vessel can havethe shape and design of high-pressure fluid vessel 18 as shown in FIGS.1A-5 . The plurality of internal supports can include internal supports42, 44, 46, and 48 as shown in FIGS. 2B-5 .

The first portion of high-pressure fluid vessel 18 can include a firsthalf of capsules 33A, 33B, 33C, 33D, and 33E of bottom compartment 24,intermediate compartments 26, 28, and 30, and top compartment 32 ofhigh-pressure fluid vessel 18, respectively. The first half of capsules33A, 33B, 33C, 33D, and 33E includes first domed ends 34A, 34B, 34C,34D, and 34E and half of semicylindrical portions 38A, 38B, 38C, 38D,and 38E. The second portion of high-pressure fluid vessel 18 can includea second half of capsules 33A, 33B, 33C, 33D, and 33E of bottomcompartment 24, intermediate compartments 26, 28, and 30, and topcompartment 32 of high-pressure fluid vessel 18, respectively. Thesecond half of capsules 33A, 33B, 33C, 33D, and 33E includes seconddomed ends 34A, 34B, 34C, 34D, and 34E and the other half ofsemicylindrical portions 38A, 38B, 38C, 38D, and 38E. In alternateembodiments, the first portion of high-pressure fluid vessel 18 and thesecond portion of high-pressure fluid vessel 18 can be any portions ofhigh-pressure fluid vessel 18 that together form high-pressure fluidvessel 18. The first portion of the high-pressure fluid vessel 18, thesecond portion of the high-pressure fluid vessel 18, and internalsupports 42, 44, 46, and 48 can all be manufactured according tostandard molding processes, including injection molding or compressionmolding.

A standard injection molding process includes the following. First amold for the part is created according to the design of the part andwill include a cavity that is shaped according to the design of thepart. The mold is positioned in a clamp adjacent to a tip of aninjection unit. The mold will include a pathway that connects the cavityof the mold with the tip of the injection unit. Pellets of material willbe placed in a hopper to be fed into a barrel of an injection unit. Theinjection unit can include a screw-type plunger that is used to move thepellets through the barrel of the injection unit towards a tip of theinjection unit. The barrel of the injection unit is heated to melt thepellets as they move through the barrel of the injection unit. At thetip of the injection unit, the pellets of material will be completelymolten. When enough molten material has accumulated at the tip, thescrew-type plunger will ram forward to force the molten material throughthe tip of the injection unit to fill the cavity of the mold. After themolten material has solidified in the mold, the clamp can be released toseparate the mold and allow the part to be removed from the mold.

A standard compression molding process includes the following. First amold for the part is created according to the design of the part andwill include a cavity that is shaped according to the design of thepart. The mold is positioned in a hydraulic press. A material is placedover or inserted into the mold. The mold can be preheated prior to thematerial being placed over or in the mold. The material is then heatedto a pliable state. The hydraulic press then compresses the pliablematerial with a top force or plug member. The pressure applied to thepliable material causes the material to form to the shape of the mold.The pressure is maintained until the material has cured, the pressure isreleased and the part can be removed from the mold.

The above includes a general description of an injection molding processand a compression molding process. The process can vary from thosedescribed above. Each of the first portion of high-pressure fluid vessel18, the second portion of high-pressure fluid vessel 18, and internalsupports 42, 44, 46, and 48 can be formed using any molding process. Thefirst portion of high-pressure fluid vessel 18, the second portion ofhigh-pressure fluid vessel 18, and internal supports 42, 44, 46, and 48are manufactured out of a fiber reinforced polymer matrix composite.

Step 206 includes positioning the plurality of internal supports in thefirst portion of the high-pressure fluid vessel. A first end of each ofinternal supports 42, 44, 46, and 48 are positioned in the first half ofhigh-pressure fluid vessel 18. Internal support 42 is positioned at theintersection of bottom compartment 24 and intermediate compartment 26;internal support 44 is positioned at the intersection of intermediatecompartment 26 and intermediate compartment 28; internal support 46 ispositioned at the intersection of intermediate compartment 28 andintermediate compartment 30; and internal support 48 is positioned atthe intersection of intermediate compartment 30 and top compartment 32.

Step 208 includes welding the plurality of internal supports to thefirst portion of the high-pressure fluid vessel. Internal supports 42,44, 46, and 48 can be welded to the first half of high-pressure fluidvessel 18 using friction stir welding, adhesive bonding, ultrasonicwelding, or any other suitable welding process. Internal support 42 iswelded to the intersection of bottom compartment 24 and intermediatecompartment 26; internal support 44 is welded to the intersection ofintermediate compartment 26 and intermediate compartment 28; internalsupport 46 is welded to the intersection of intermediate compartment 28and intermediate compartment 30; and internal support 48 is welded tothe intersection of intermediate compartment 30 and top compartment 32.

Step 210 includes positioning the second portion of the high-pressurefluid vessel around the plurality of internal supports and adjacent tothe first portion of the high-pressure fluid vessel. The second half ofhigh-pressure fluid vessel 18 is positioned over a second end of each ofinternal supports 42, 44, 46, and 48. Internal support 42 is positionedat the intersection of bottom compartment 24 and intermediatecompartment 26; internal support 44 is positioned at the intersection ofintermediate compartment 26 and intermediate compartment 28; internalsupport 46 is positioned at the intersection of intermediate compartment28 and intermediate compartment 30; and internal support 48 ispositioned at the intersection of intermediate compartment 30 and topcompartment 32. An edge of the second half of high-pressure fluid vessel18 is also positioned adjacent to an edge of the first half ofhigh-pressure fluid vessel 18.

Step 212 includes welding the second portion of the high-pressure fluidvessel to the plurality of internal supports. Internal supports 42, 44,46, and 48 can be welded to the first half of high-pressure fluid vessel18 using friction stir welding, adhesive bonding, ultrasonic welding, orany other suitable welding process. Internal support 42 is welded to theintersection of bottom compartment 24 and intermediate compartment 26;internal support 44 is welded to the intersection of intermediatecompartment 26 and intermediate compartment 28; internal support 46 iswelded to the intersection of intermediate compartment 28 andintermediate compartment 30; and internal support 48 is welded to theintersection of intermediate compartment 30 and top compartment 32.

Step 214 includes welding the second portion of the high-pressure fluidvessel to the first portion of the high-pressure fluid vessel. Thesecond half of high-pressure fluid vessel 18 can be welded to the firsthalf of high-pressure fluid vessel 18 using friction stir welding,adhesive bonding, ultrasonic welding, or any other suitable weldingprocess. The edge of the second half of high-pressure fluid vessel 18 iswelded to the edge of the first half of high-pressure fluid vessel 18.

Manufacturing high-pressure fluid vessel 18 using steps 200-214 asdescribed will create a leak-tight vessel that is capable of storing afluid. High-pressure fluid vessel 18 can be used on an aircraft.High-pressure fluid vessel 18 is made out of a fiber reinforced polymermatrix composite, which will result in high-pressure fluid vessel 18being lightweight. Further, the fiber reinforced polymer matrixcomposite can be potable water safe, eliminating the need for using aliner in high-pressure fluid vessel 18.

FIG. 8 is a flow chart of a second method for manufacturinghigh-pressure fluid vessel 18. FIG. 8 includes steps 300-312. Steps300-312 can be used to manufacture high-pressure fluid vessel 18 shownin FIGS. 1A-5 , high-pressure fluid vessel 118 shown in FIG. 6 , or anyother high-pressure fluid vessel. The following discussion will focus onhigh-pressure fluid vessel 18, but it is understood that this processcan be used to manufacture any other suitable tank.

Step 300 includes forming a plurality of liners with a molding process.The molding process can include blow molding, rotational molding, orinjection molding. The plurality of liners can include bottom liner 62,intermediate liners 64, 66, 68, and top liner 70 as shown in FIG. 4 .Bottom liner 62, intermediate liners 64, 66, 68, and top liner 70 can bemanufactured according to standard molding process, such as blowmolding, rotational molding, or injection molding.

A standard blow molding process includes the following. First a mold forthe part is created according to the design of the part and will includea cavity that is shaped according to the design of the part. The mold ispositioned in a clamp adjacent to a tip of a blow molding apparatus. Themold will include a pathway that connects the cavity of the mold withthe tip of the blow molding apparatus. There are three general blowmolding processes: extrusion blow molding, injection blow molding, andinjection stretch blow molding. Extrusion blow molding includes meltinga material and forming it into a parison (or hollow tube). The parisonis then positioned in the mold and air is blown into the parison toinflate in the mold. The inflated material then will form to the cavityin the mold. Both injection blow molding and injection stretch blowmolding include injection molding a preform with a standard injectionmolding process and then positioning the preform in a blow moldingapparatus to be inflated and cooled.

A standard rotational molding process includes the following. First amold for the part is created according to the design of the part andwill include a cavity that is shaped according to the design of thepart. A material is placed in the mold. Then mold can be heated priorthe material being placed in the mold. The mold is then slowly rotatedand heated as needed to soften the material in the mold. The softenedmaterial will then disperse and stick to the walls of the mold. Thematerial and the mold are cooled while the mold continues to rotate toprevent the material from sagging or deforming during the coolingprocess. Once the material has cooled, the mold can be opened and thepart can be removed.

A standard injection molding process includes the following. First amold for the part is created according to the design of the part andwill include a cavity that is shaped according to the design of thepart. The mold is positioned in a clamp adjacent to a tip of aninjection unit. The mold will include a pathway that connects the cavityof the mold with the tip of the injection unit. Pellets of material willbe placed in a hopper to be fed into a barrel of an injection unit. Theinjection unit can include a screw-type plunger that is used to move thepellets through the barrel of the injection unit towards a tip of theinjection unit. The barrel of the injection unit is heated to melt thepellets as they move through the barrel of the injection unit. At thetip of the injection unit, the pellets of material will be completelymolten. When enough molten material has accumulated at the tip, thescrew-type plunger will ram forward to force the molten material throughthe tip of the injection unit to fill the cavity of the mold. After themolten material has solidified in the mold, the clamp can be released toseparate the mold and allow the part to be removed from the mold.

The above includes a general description of blow molding processes, arotational molding process, and an injection molding process. Theprocesses can vary from those described above. Each of bottom liner 62,intermediate liners 64, 66, 68, and top liner 70 can be formed using anymolding process.

Bottom liner 62 will include a capsule portion to form bottomcompartment 24 and a flat portion that will form part of internalsupport 42. Intermediate liner 64 will include a capsule portion to formintermediate compartment 26, a flat portion that will form part ofinternal support 42, and a flat portion that will form part of internalsupport 44. Intermediate liner 66 will include a capsule portion to formintermediate compartment 28, a flat portion that will form part ofinternal support 44, and a flat portion that will form part of internalsupport 46. Intermediate liner 68 will include a capsule portion to formintermediate compartment 30, a flat portion that will form part ofinternal support 46, and a flat portion that will form part of internalsupport 48. Top liner 70 will include a capsule portion to form tocompartment 32 and a flat portion that will form part of internalsupport 48. The capsule portion of each of bottom liner 62, intermediateliners 64, 66, 68, and top liner 70 will include a first domed end, asecond domed end, and a semicylindrical portion extending between thefirst domed end and the second domed end.

Step 302 includes wrapping a composite material around each of theliners to form a plurality of compartments. The plurality ofcompartments can includes bottom compartment 24, intermediatecompartments 26, 28, and 30, and top compartment 32 as shown in FIGS.2A-5 . Bottom liner 62, intermediate liners 64, 66, 68, and top liner 70can be wrapped with a composite material to form bottom compartment 24,intermediate compartments 26, 28, and 30, and top compartment 32,respectively.

Bottom liner 62, intermediate liners 64, 66, 68, and top liner 70 can bewrapped with a continuous fiber composite or a hybrid of continuous anddiscontinuous fiber composites. Fibers have greater lengths thandiameters and the length-to-diameter ratio is known as the aspect ratio.Continuous fiber composites have fibers with long aspect ratios anddiscontinuous fiber composites have fibers with short aspect ratios.Continuous fiber composites also tend to have a preferred orientation,while discontinuous fiber composites have a random orientation. Fibersin composite materials provide structural reinforcement for thecomposite material. The composite material used to wrap bottom liner 62,intermediate liners 64, 66, 68, and top liner 70 can be fiber tows, afabric, or fiber tapes that include either continuous fibers or a hybridof continuous and discontinuous fibers in a composite material. Thefiber can be carbon fiber, glass fiber, aramid fiber, or any othersuitable fibers. The composite material can be a thermoset matrixmaterial or any other suitable composite material.

Bottom liner 62, intermediate liners 64, 66, 68, and top liner 70 willdefine the shape of bottom compartment 24, intermediate compartments 26,28, and 30, and top compartment 32, respectively. As such, bottomcompartment 24 will include capsule 33A and a flat portion that willform part of internal support 42. Capsule 33A will include first domedend 34A, second domed end 36A, and semicylindrical portion 38A.Intermediate compartment 26 will include capsule 33B, a flat portionthat will form part of internal support 42, and a flat portion that willform part of internal support 44. Capsule 33B will include first domedend 34B, second domed end 36B, and semicylindrical portion 38B.Intermediate compartment 28 will include capsule 33C, a flat portionthat will form part of internal support 44, and a flat portion that willform part of internal support 46. Capsule 33C will include first domedend 34C, second domed end 36C, and semicylindrical portion 38C.Intermediate compartment 30 will include capsule 33D, a flat portionthat will form part of internal support 46, and a flat portion that willform part of internal support 48. Capsule 33D will include first domedend 34D, second domed end 36D, and semicylindrical portion 38D. Topcompartment 32 will include capsule 33E and a flat portion that willform part of internal support 48. Capsule 33E will include first domedend 34E, second domed end 36E, and semicylindrical portion 38E.

Step 304 includes forming an aperture in each of the plurality ofcompartments. The apertures can include apertures 50A, 50B, 50C, and50D, as shown in FIGS. 2B-3 . Apertures 50A, 50B, 50C, and 50D areformed in bottom compartment 24, intermediate compartments 26, 28, and30, and top compartment 32. Apertures 50A, 50B, 50C, and 50D can beformed using any suitable process.

Apertures 50A, 50B, 50C, and 50D are each formed in two compartments.Aperture 50A is formed in the flat portion of bottom compartment 24 andone of the flat portions of intermediate compartment 26. Aperture 50B isformed in one of the flat portions of intermediate compartment 26 andone of the flat portions of intermediate compartment 28. Aperture 50C isformed in one of the flat portion of intermediate compartment 28 and oneof the flat portions of intermediate compartment 30. Aperture 50D isformed in one of the flat portion of intermediate compartment 30 and theflat portion of intermediate compartment 32.

Step 306 includes positioning the plurality of compartments adjacent toone another. Bottom compartment 24, intermediate compartments 26, 28,and 30, and top compartment 32 are positioned adjacent to one another toform the shape of high-pressure fluid vessel 18. The flat portions ofbottom compartment 24, intermediate compartments 26, 28, and 30, and topcompartment 32 are positioned adjacent to one another.

The flat portion of bottom compartment 24 is positioned adjacent to oneof the flat portions of intermediate compartment 26 to align apertures50A in each. One of the flat portions of intermediate compartment 26 ispositioned adjacent to one of the flat portions of intermediatecompartments 28 to align apertures 50B in each. One of the flat portionsof intermediate compartment 28 is positioned adjacent to one of the flatportions of intermediate compartments 30 to align apertures 50C in each.One of the flat portions of intermediate compartment 30 is positionedadjacent to the flat portions of top compartments 32 to align apertures50D in each.

Positioning the bottom compartment 24, intermediate compartments 26, 28,and 30, and top compartment 32 adjacent to one another will forminternal supports 42, 44, 46, and 48. Internal supports 42, 44, 46, and48 will include a first liner layer, two layers of composite material,and a second liner layer. Apertures 50A, 50B, 50C, and 50D will extendthrough internal supports 42, 44, 46, and 48, respectively.

Step 308 includes wrapping a composite material around the plurality ofcompartments to form a high-pressure fluid vessel. Bottom compartment24, intermediate compartments 26, 28, and 30, and top compartment 32 canbe wrapped with a composite material to form high-pressure fluid vessel18.

Bottom compartment 24, intermediate compartments 26, 28, and 30, and topcompartment 32 can be wrapped with a continuous fiber composite or ahybrid of continuous and discontinuous fiber composites. Fibers incomposite materials provide structural reinforcement for the compositematerial. The composite material used to wrap bottom compartment 24,intermediate compartments 26, 28, and 30, and top compartment 32 can befiber tows, a fabric, or fiber tapes that include either continuousfibers or a hybrid of continuous and discontinuous fibers in a compositematerial. The fiber can be carbon fiber, glass fiber, aramid fiber, orany other suitable fibers. The composite material can be a thermosetmatrix material or any other suitable composite material. Wrappinghigh-pressure fluid vessel 18 will result in walls of capsules 33A, 33B,33C, 33D, and 33E of high-pressure fluid vessel 18 having a liner andtwo layers of composite material.

Manufacturing high-pressure fluid vessel 18 using steps 300-308 asdescribed will create a leak-tight vessel that is capable of storing afluid. High-pressure fluid vessel 18 can be used on an aircraft.High-pressure fluid vessel 18 is made out of a continuous fibercomposite or a hybrid of continuous and discontinuous fiber composites,which will result in high-pressure fluid vessel 18 being lightweight.

Discussion of Possible Embodiments

The following are non-exclusive descriptions of possible embodiments ofthe present invention.

A method of manufacturing a high-pressure fluid vessel includes forminga first portion of a high-pressure fluid vessel with a molding process.The high-pressure fluid vessel includes a stack of capsules. Eachcapsule includes a first domed end, a second domed end, and asemicylindrical portion extending between and connecting the first domedend to the second domed end. The method further includes forming asecond portion of a high-pressure fluid vessel with the molding process.The second portion of the high-pressure fluid vessel is positionedadjacent to the first portion of the high-pressure fluid vessel. Thesecond portion of the high-pressure fluid vessel is welded to the firstportion of the high-pressure fluid vessel.

The method of the preceding paragraph can optionally include,additionally and/or alternatively, any one or more of the followingfeatures, configurations and/or additional components:

Wherein the first portion of the high-pressure fluid vessel includes afirst half of each of the capsules of the high-pressure fluid vesselincluding the first domed ends and half of the semicylindrical portions,and wherein the second portion of the high-pressure fluid vesselincludes a second half of each of the capsules of the high-pressurefluid vessel including the second domed ends and half of thesemicylindrical portions.

Wherein the molding process is selected from the group consisting ofinjection molding, compression molding, and combinations thereof.

Wherein welding the second portion of the high-pressure fluid vessel tothe first portion of the high-pressure fluid vessel includes frictionstir welding the second portion of the high-pressure fluid vessel to thefirst portion of the high-pressure fluid vessel.

The method further includes forming a plurality of internal supportswith the molding process; positioning the plurality of internal supportsin the first portion of the high-pressure fluid vessel; welding theplurality of internal supports to the first portion of the high-pressurefluid vessel; positioning the second portion of the high-pressure fluidvessel around the plurality of internal supports; and welding theplurality of internal supports to the second portion of thehigh-pressure fluid vessel.

Wherein positioning the plurality of internal supports in the firstportion of the high-pressure fluid vessel includes positioning each ofthe plurality of internal supports between adjacent capsules.

Wherein positioning the second portion of the high-pressure fluid vesselaround the plurality of internal supports includes positioning each ofthe plurality of internal supports between adjacent capsules.

Wherein welding the plurality of internal supports to the first portionof the high-pressure fluid vessel includes friction stir welding theplurality of internal supports to the first portion of the high-pressurefluid vessel.

Wherein welding the plurality of internal supports to the second portionof the high-pressure fluid vessel includes friction stir welding theplurality of internal supports to the second portion of thehigh-pressure fluid vessel.

A method of manufacturing a high-pressure fluid vessel includes forminga plurality of liners with a molding process. A first composite materialis wrapped around each of the liners to form a plurality ofcompartments. An aperture is formed in each of the plurality ofcompartments. The plurality of compartments are positioned adjacent toone another. A second composite material is wrapped around the pluralityof compartments to form a high-pressure fluid vessel.

The method of the preceding paragraph can optionally include,additionally and/or alternatively, any one or more of the followingfeatures, configurations and/or additional components:

Wherein the first composite material and the second composite materialare continuous fiber composite materials that include a fiber selectedfrom the group consisting of a carbon fiber, a glass fiber, an aramidfiber, and combinations thereof.

Wherein the first composite material and the second composite materialare a hybrid of a continuous and discontinuous fiber composite materialthat include a fiber selected from the group consisting of a carbonfiber, a glass fiber, an aramid fiber, and combinations thereof.

Wherein the plurality of liners are formed out of a plastic material.

Wherein the molding process is selected from the group consisting ofblow molding, rotational molding, injection molding, and combinationsthereof.

Wherein the high-pressure fluid vessel further includes a stack ofcapsules, wherein each capsule includes a first domed end, a seconddomed end, and a semicylindrical portion extending between andconnecting the first domed end to the second domed end.

Wherein forming a plurality of liners includes forming a plurality ofliners with a capsule portion and a flat portion.

Wherein wrapping a first composite material around each of the liners toform a plurality of compartments includes forming a plurality ofcompartments that each have a capsule and a flat portion.

Wherein forming an aperture in each of the plurality of compartmentsincludes forming an aperture in the flat portion of each of theplurality of compartments.

Wherein positioning the plurality of compartments adjacent to oneanother includes positioning the flat portion of the first capsuleadjacent to the flat portion of the second capsule.

The method further includes aligning an aperture in the flat portion ofthe first capsule with an aperture in the flat portion of the secondcapsule.

While the invention has been described with reference to an exemplaryembodiment(s), it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiment(s) disclosed, but that theinvention will include all embodiments falling within the scope of theappended claims.

The invention claimed is:
 1. A method of manufacturing a high-pressurefluid vessel, the method comprising: forming a plurality of liners witha molding process; wrapping a first composite material around each ofthe liners to form a plurality of compartments; forming an aperture ineach of the plurality of compartments; positioning the plurality ofcompartments adjacent to one another to form a stack of capsules,wherein each capsule includes a first domed end, a second domed end, anda semicylindrical portion extending between and connecting the firstdomed end to the second domed end; and wrapping a second compositematerial around the plurality of compartments to form the high-pressurefluid vessel.
 2. The method of claim 1, wherein the first compositematerial and the second composite material are continuous fibercomposite materials that include a fiber selected from the groupconsisting of a carbon fiber, a glass fiber, an aramid fiber, andcombinations thereof.
 3. The method of claim 1, wherein the firstcomposite material and the second composite material are a hybrid of acontinuous and discontinuous fiber composite material that include afiber selected from the group consisting of a carbon fiber, a glassfiber, an aramid fiber, and combinations thereof.
 4. The method of claim1, wherein the plurality of liners are formed out of a plastic material.5. The method of claim 1, wherein the molding process is selected fromthe group consisting of blow molding, rotational molding, injectionmolding, and combinations thereof.
 6. The method of claim 1, whereinforming the plurality of liners includes forming the plurality of linerswherein each liner has a capsule portion and a flat portion.
 7. Themethod of claim 6, wherein wrapping the first composite material aroundeach of the liners to form a plurality of compartments includes formingthe plurality of compartments wherein each of the plurality ofcompartments has a capsule portion and a flat portion.
 8. The method ofclaim 7, wherein forming the aperture in each of the plurality ofcompartments includes forming the aperture in the flat portion of eachof the plurality of compartments.
 9. The method of claim 8, whereinpositioning the plurality of compartments adjacent to one anotherincludes positioning the flat portion of a first capsule adjacent to theflat portion of a second capsule.
 10. The method of claim 9, and furthercomprising: aligning the aperture in the flat portion of the firstcapsule with the aperture in the flat portion of the second capsule.